Pile fabric floor covering



Nov. 27, 1951 R, J. JACKSON 2,576,791

PILE FABRIC FLOOR COVERING Fld Jan. 24, 1947 2 SHEETS-SHEET l /0 l a a e34 I c' c` [j 3 1,2 5a. I 1.5 [5a ze l.; d

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Nov. 27, 1951 R. J. JACKSON 2,576,791

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Filed Jan. 24, 1947 2 SHEETS-SHEET ICCO oooxocnoxoool 'POOOOXXXXOOOXXXOO Q1 D D Q /XXOOOXXOOXXOOXXX BY 'A7 Patented Nov. 27, 1951 PILE FABRIC FLOOR COVERING Robert J. Jackson, Hazardville, Conn., assigner,

by mesne assignments, to Bigelow-Sanford Carpet Company, Inc., New York, N. Y., a corporation of Delaware Application January 24, 1947, Serial No. 723,965

18 Claims.

This invention relates to woven pile fabrics. particularly carpets and rugs.

A principal object of the invention is to provide a. pile fabric door covering having on the surface of the fabric high and low pile loops which may be arranged in rows in warpwise and weftwise relation to each other in any pattern desired.

An important feature of this invention is the employment in a wire loom of sets of two or more pile wires having high and low portions so placed as to produce .the pattern desired.

Other objects and features will appear from the following description taken in conjunction with the accompanying drawings in which:

Fig. 1 is a side view of a pile wire of a set of pile wires;

Fig. 1A is a side view of a modification of the wire shown in Fig. 1;

Fig. 2 is a warpwise diagrammatic 'cross-sectional view of a fabric with some of the pile wires inserted;

Fig. 3 is the same view as in Fig. 2 after one of the wires has been withdrawn;

Fig. 4 is the same view as in Fig. 3 after another wire has been withdrawn; and,

Fig. 5 is a diagram of a weave produced with y a repeat set of four wires.

Any known form of pile wire loom, such as that described in Patent No. 1,840,856, may be employed in the application of my invention.

A preferred weave of a common type is illustrated in Figs. 2-4, in which I'I represents the stuiIer warps, I9 the binder warps, I8 the holding weft shots above the stufi'er warps and I8' the weft shots below those warps. I6 are the pile warps which are strong enough to render without breaking under a holding weft shot'when pulled by the high portion of a wire as will bef discribed. The sections shown in Figs. 2-4 show the high portions of some wires and the low portions of others.

The wires are formed with high` and low portions according to the pattern of high and low warp loops desired. Fig. 1 shows such a wire. This wire may have a high portion I0 at the end beyond the inner selvage of the fabric when the v wire is fully inserted. High portions Iza, I2b and I2c are located on the pile wire in accordance with the desired pattern and may be of any numi 2 the high portions in the direction of the withdrawal of the pile wire, are of the proper slope, not over to raise the loops formed over the low portions of the wire to the height of the high portions as the wire is withdrawn.

Fig. lA shows a pile wire II', which diifers from the Wire II of Fig. 1 in the omission of the high portion I0.' It has `portions I3a and I3d extending where the selvages of the fabric are to be located. In the case where the pile warps are wound on the usual warp beam, the height of the portions I3a' and I3d is such that the same lengths of pile warps are drawn over these portions as over the other portions of the wires in a repeat set.

I prefer to weave the fabric on a loom pro vided with the usual warp beam. In such case the shapes of the wires in a repeat set to impart a given pattern are such that every pile warp is of the same length as it passes over the high portions and the low portions of a set of wires. To secure this effect the sums of the heights of the portions of a set of wires warpwise are the same. Thus every pile warp is drawn evenly from the warp beam without variation in length.

If, however, the wires are used on a loom provided with spools on which the pile warps are wound, the shapes of the wires are not so limited, because the drawoff of the pile warps need not be the same for a set of wires.

Figs. 2, 3 and 4 illustrate an example of the method of forming high or low pile loops and show the usual pile yarns I6, stuffer warps I1, weft threads I8 and I8' and. binder warps I9.

In Fig. 2, a pile wire has already been withdrawn from under loop I6 and pile wires IIa, IIb, IIcl IId and Ile are under loops IBA, ISB, IBC, I6D and ISE respectively.` All loops of the weftwise row on which the loop I6' is located are high, having been either looped over high por.

tions of the wire under loop I6' or raised by such portions of said Wire as it was withdrawn.

In Fig. 3. the pile wire IIa, Fig. 2, has been withdrawn forming the high loop ISA which has and, as said loop was originally high, it does not draw yarn from the previous loop I 6A which consequently remains high.

Fig. 5 is a diagrammatic illustration of the cffect of a repeat set of four wires, a, b, c and d on pile warps taken from a warp beam so that the lengths of the warps woven over the wires of the set are the same. The-wire a at the top of the -beam or spools.

figure may be assumed to be the leading wire.

yWhen it is Withdrawnitleaves all the loops high crosses and the low loops by small circles in Fig. 5..

When the wire b is withdrawn it leaves allthe loops in row B high and when the wire c is withdrawn it reduces the height of the loops of row B the warps of which pass over the low portions of wire c, etc. The pattern of the rows of high and low loops, both warpwise and weftwise, -is shown by the rows of crosses and small circles and corresponds to the arrangement of` the highand low portions of the wires in the set.

As an example, Fig. 5 illustrates a repeat set of four Wires. A repeat set may include any desired number of Wires. If the warps are wound on the warp beam the lengths of the warps woven over the wires of a repeat set should be the same. If the warps are wound on separate spools the lengths of the warps in a repeat set need not be the same.

All loops in the weftwise row are high when a wire in that row is withdrawn. The loops which pass over a low portion of a wire are raised by the high portions of the wire as it is withdrawn from by a more regular and uniform appearance,

l as the low loops from which they originate have and drawn down the loops in the same warpwise rows in the preceding weftwise row; but, the loops which pass over the high portion of the withdrawn wire leave the high loops in the preceding weftvwise row high.

The effect of this method of weaving, is that there are four kinds of loops:

A-high loops, Woven high, and remaining high B-high loops, woven low, raised to high and remaining high;

C-low loops, woven high and pulled down to low, and

D-low loops, woven low, raised to high. and pulled down to low.

These different kinds of loops, both high and low, are conspicuous on the face of the fabricand are distinguishable from each other.

A-the high loops which were woven high and are not disturbed by the; wire withdrawal have a loose, full and irregular appearance. 'I'he num-'- ber of turns or twists in the yarns comprising these loops remains undisturbed, that is. it is the same per unit of length as in the yarn on the This, I call, a normal twist. These loops are characterized by a noticeable twist, fullness and varied angularity, which are lacking in the high loops woven low and raised.

B-the loops which were woven low and raised high by the withdrawal of a wire appear very close together and their yarns have comparatively little twist, which I call a subnormal twist. This is caused by the twist in the low woven loop being extended over the additional length of the yarn present in the loop after it has been raised. These loops are characterized by a uniformity in shape and direction of lay and by a noticeably low twist.

C--the loops which are woven high and pulled down low are tightlyr twisted, as the twist inthe of the low loop. This, I call a superno'rmal twist.

' high loops is concentrated in the shorter-length not as many twists in the yarn as the longer high loop from which the C low loops originate. I call the twist in the low D loops a twist less than s upernormal.

Thus, the loops, A, B, C and D are characterized as to twist:

A--normal twist B--subnormal twist C--supernormal twist D-less than supernormal twist While I do not wish to be bound by any theory, I believe that this difference in degree'of twist in the different kindsV of loops can be explained as follows. The warp yarn overlying a wire just prior to withdrawal of the wire is tightly bound in the backing structure of the fabric and against the stuffer warps, adjacent pile yarns, binder warps and the holding weft. When a pile warp so confined and engaged by adjacent strands is forced by the withdrawal of a wire to slide be neath a holding weft I8 it is pinched as it slides so that there is a tendency for the twist to be held back. Accordingly, as a high loop is pulled down yarn is withdrawn from the loop but some or all of the twist in this withdrawn yarn is held baci; so that it is added to the twist present in the yarn remainingin the loop, with the result that the pulled-down loop contains more turns of twist per unit length than it did before it -was pulled down. Similarly, when a low loop is pulled up it 'gains in length without a corresponding gain'in number of turns of twist, whereby the turns perunit length are decreased. Whatever the explanation may be, however, the fact remains that my described method of weaving necessarily and inher-4 ently results in loops in the same warp yarn which differ from each other in the number'of turns of twist per unit length present in the yarnof which they are composed, and, consequently, differ in their appearance and textural effect.

In the foregoing I have described the application of my invention to a fabric in which there are two sets of binder warps which cross each other, but my invention is applicable to a fabric in which there is a single set of binder warps. In one form of such a weave the upper weft shots' may be the holding weft shots around which the pile warps are looped. In another form of such weave with a single set of binder warps the lower weft shots may be the holding weft shots around which the pile warps are looped to form a pattern on the back of the fabric. In the latter case the fabric should be so woven that the pile. loops may be drawn down around the lower weftl shots when a pile warp, which has been woven over a low portion of the succeeding wire, is raised by the withdrawal of that wire. My invention is also applicable to a Jacquard weave in which there are areas in which a pile warp is raised to the surface for a series of consecutive loops. In such case, as in the applications of my invention to other weaves, s'uch a series of pile loops may include two or more high loops in succession. My invention is applicable to any fabric in which may be formed a pattern of high and low pile warp loops which corresponds to the high, aridi l low portions of a s'et of wires.

Weaving processes, looms and pile wires for the manufacture of my pile fabric are disclosed and claimed in, my divisional application Serial No. 785,640 filed November 13, 1947, now Patent No. 2,516,465; g

Iclaim:

1. A pile fabric floor covering having a pattern formed of groups of high warp loops and of groups of low warp loops, and wherein a weftwise row of loops includes both high and low loops, the warps of said pattern being separated by binder warps and the binder warps being separated by stuffer warps. a series of holding wefts disposed on one side of said stuier warps and a series of non-` holding wefts disposed on the other side of said stuiler warps, each group of high loops comprising a plurality of loops in sequence in the same pile warp, the high and low loops in weftwise rows forming a pattern corresponding to the high and low portions of wires of a set over which the pile warps were woven.

2. A woven pile fabric floor covering having -a warp pile i ace comprising high and low warp pile loops arranged to form a pattern wherein a weftwise row includes both high and low pile loops and wherein high and low pile loops are located in the pattern in any desired predetermined relative order and are woven into a backing structure including stuffer warps, a series of holding wefts lying on one side of the stufler warps, a series lof non-holding wefts lying on the other side of the stuffer warps, and a binder warp looped about wefts of both series of wefts and holding the wefts in position against the stufler warps, each pile warp of said fabric forming a loop around each weft of the series of holding wefts, the high and low loops in weftwise rows forming a pattern corresponding to the high and low portions of wires of a set over which the pile warps were woven.

3. A woven pile fabric floor covering having a warp pile face comprising high and low warp pile loops arranged to form a pattern wherein a weftwise row includes both high and low pile loops and wherein high and low-pile loops are located in any desired predetermined relative order and are woven into a backing structure including stufi'er warps, a series of weft shotsk lying on one side of the stuifer warps, a series of weft shots `1ying on the other side of the stuifer warps, and a binder warp looped about wefts of both series of i wefts and holding the wefts in position against the stuffer warps, said fabric including a pile warp forming a low pile loop between and immediately adjacent to two high pile loops of the 4same warp, the high and low loops in weftwise rows forming a pattern corresponding to thehigh and low portions of wires of a set over which the pile warps were woven.

4. A woven pile fabric floor covering having a warp pile face comprising vhigh and low w'arp pile loops varranged to form a pattern wherein a wei'twise row includes both high and low pile loops and wherein high and low pile loops are lo-' cated'in any .desired predetermined relative order and are woven 'into a backing structure including stuifer warps, a series of weft shots lying on one side of the stufler warps, a series of weft shots lying on the other side of the stufler warps, and a binder warp looped about wefts of both series of wefts and holding the wefts in position against the stuffer warps, said fabric including a pile warp 'forming a high pile loop between and immediately adjacent to two other pile loopsl of the same warp, the high and low loops `in weftwise vrows forming a pattern corresponding to the high and low portions oi' wires of a set over which the pile warps were woven.

5. A woven pile fabric floor covering having a warp pile face comprising high and low warp pile loops arranged to form a pattern wherein a weftwise row includes both high and low pile loops and wherein high and low pile loops are located in any desired predetermined relative order and are woven into a backing structure including stuer-warps, a series of weft shots lying on one side of the stuifer warps, a series of weft shots lying on the other side of the stuffer warps, and a binder warp looped about wefts of both series of wefts and holding the wefts in position against the stuifer warps. said fabric including a pile warp forming two adjacent pile loops of greater height than the lowest pile loop of said face, the high and low loops in weftwise rows forming a pattern corresponding to the high and low portions of wires of a set over which the pile warps were woven.

6. A pile fabric floor covering having a pattern formed of groups of 'high warp loops and of groups of low warp loops, and wherein a weftwise row of loops includes both high and low loops, the warps of said pattern being separated by binder warps and the binder warps being separated by stuier warps, a series of holding wefts disposed on one side of said stuffer warps and a series of non-holding wefts disposed on the other sideof said stuffer warps, each group of high loops comprising a plurality of loops in sequence in the same pile warp, said pattern having a multiplicity of sequences of a high loop and a low loop in the same pile warp.

7. A pile fabric floor covering having a pattern formed of groups of high warp loops and of groups of low warp loops, and wherein a weftwise row of loops includes both high and low loops, the warps of said pattern being separated by binder warps and the binder warps being separated by stuffer warps, a series of holding wefts disposed on one side of said stuffer warps and a series of non-holding wefts disposed on the other side of said stuifer warps, all of the pile warps being raised into the face of the fabric to form pile loops between every two holding wefts.

8. A pile fabric door covering having a pattern formed of groups of high warp loops and of groups of `low warp loops, and wherein a Weftwise row of loops includes both high and low loops, the warps of said pattern being separated by binder warps and the binder warps being separated by stuffer warps, a series of holding wefts disposed on one side of said stuifer warps and a series of non-holding wefts disposed on the other side of said stuffer warps, e'ach group of high loops comprising a plurality of loops in sequence in the same pile warp, some of the pile warps containing sequences of two high loops and a low loop, some of the -pile warps containing sequences of a low loop, a high loop and a low loop, and someA of the pile warps containing sequences of a high loop, a low loop and a high loop.

9. A woven pile fabric floor covering having high pile loops and low pile loops in the same warp, the `yarn forming some of said high loops having a normal twist, the yarn forming others of said high loops having a subnormal twist, the

yarn forming some of said low loops having a' high loops and low loops in the same warp, the yarn forming some of said high loops having a normal twist, the yarn forming others of said high loops having a subnormal twist and the yarn forming some of said low loops having a supernormal twist.

1l. A woven pile fabric floor covering having pile loops in the same warp of substantially the high pile loops and low pile loops in the same warp, the yarn forming some of said high loops having a subnormal twist, the yarn forming some of said low loops having a supernormal twist and the yarn forming others of said low loops having a twist less than supernormal.

14. A woven pile fabric floor covering having high pile loops and low pile loops in the same warp, the yarn forming some of said high loops having a normal twist, the yarn forming some of said low loops having a supernormal twist and the yarn forming others of Said low loops having a twist less than supernormal.

15. A woven pile fabric floor covering having a .warp pile face comprising high and low warp pile loops arranged to form a pattern wherein a weftwise row includes both high and low pile loops and wherein high and low pile loops are woven into a backing structure including stuiler warps, a series of weft shots lying on one side of the stuifer warps, a series of weft shots lying on the other side of the stuifer warps', and a binder warp looped about wefts of both series of wefts and holding the wefts in position against the stuller warps, said fabric including a pile warp forming two adjacent pile loops of greater height than the lowest pile loop of said face, a plle warp forming a high pile loop between and immediately adjacent to two other pile loops of the same warp, and a pile warp forming a low pile loop between and immediately adjacent to two high pile loops of the same warp.

16. A pile fabric floor covering having a pattern formed of groups of high warp loops and of groups of low warp loops, and wherein a weftwise row of loops includes both high and low loops, the warps of said pattern being separated by binder warps and the binder warps being separated by stutter warps, a series of holding wefts disposed on one side of said stuffer warps and a series of nonholding wefts disposed on the other side of said stulfer warps, the yarn forming some of said high loops having less twist per unit length than the yarn forming others ofsaid high loops, each group of high loops comprising a plurality of loops in sequence in the same pile warp.

17. A pile fabric iloor covering having a pattern formed of groups of high warp loops and of groups of low warp loops, and wherein a weftwise row of loops includes both high and low loops, the warps of said pattern being separated by binder warps and the binder warps being separated by stuffer warps, a series of holding wefts disposed on one side of said stuffer warps and a series of non-holding wefts disposed on the other side of said stuffer warps, the yarn forming some of said low loops having less twist per unit length than the yarn 8 forming others of said low loops, each group of high loops comprising a plurality of loops in sequence in the same pile warp.

18. A pile fabric floor covering having a pattern formed of groups of high warp loops and of groupsl of low warp loops, and wherein a weftwise row of loops includes both high and low loops, the warps of said pattern being separated by binder warps and the binder warps being separated by stuffer warps, a series of holding wefts disposed on one side of said stuier warps and a series of non-holding wefts disposed on the other side of said stuifer warps, the yarn forming some of said high loops having a normal twist, the yarn forming others of said high loops having a subnormal twist, the yarnforming some of said low loops having a supernormal twist and the yarn forming others of said low loops having a twist less than supemormal, each group of highloops comprising a plurality of loops in sequence in the same pile warp.

ROBERT J. JACKSON.

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Weaving Fabrics Textile Designing; International Textbook Co. of Scranton; 1906; sec. 83. 

